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<p>To address the inherent flammability and severe smoke release of polypropylene (PP) that restrict its safety-critical applications, a novel intumescent flame retardant (IFR) system was developed in this study. Ammonium polyphosphate (APP) was efficiently coated with halloysite nanotubes (HNTs) using 3-glycidoxypropyltrimethoxysilane (KH560) as a molecular bridge to obtain a composite flame retardant (HNTs@APP) with enhanced thermal stability and charring performance. This component was synergistically combined with tris(2-hydroxyethyl) isocyanurate (THEIC) and zinc borate (ZB) to construct an efficient IFR system. Remarkably, the experimental results show that the limiting oxygen index (LOI) of composite PP2, which is composed of only 25 wt% HNTs@APP/THEIC, reaches 32.5%; with the introduction of ZB, the flame retardant performance of the composite is further improved. The silicon-boron synergistic effect can efficiently catalyze the dehydration and crosslinking of the polymer matrix, significantly enhance the thermal stability and compactness of the residual carbon layer, thereby synergistically improving the flame retardant, smoke suppression and mechanical properties of the composite. Among them, the LOI of PP4 is increased to 34.5%, the peak heat release rate (pHRR) and total smoke production (TSP) are reduced to 162 kW/m<sup>2</sup> and 0.6 m<sup>2</sup>, decreasing by 88% and 95% compared with pure PP, respectively, and the lowest I<sub>D</sub>/I<sub>G</sub> (0.58) is achieved. Meanwhile, its tensile strength and elongation at break are increased to 24.81&#xa0;MPa and 44.87%, respectively, effectively alleviating the deterioration of the mechanical properties of the PP matrix caused by the addition of flame retardants. This study realizes the synergistic improvement of flame retardant and smoke suppression properties of PP materials at a low flame retardant addition amount, providing a new technical path with good application prospects for the application of PP in safety-critical fields such as electronic and electrical enclosures and building fireproof materials.</p>

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Intumescent flame-retardant polypropylene based on halloysite nanotube-modified ammonium polyphosphate and zinc borate: Synergistic effect and smoke suppression

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Wenqian Zhou,
  • Hongxiang Ou,
  • Xiaoyan Li,
  • Zhe Tu,
  • Honglai Xue,
  • Fang Zhu

摘要

To address the inherent flammability and severe smoke release of polypropylene (PP) that restrict its safety-critical applications, a novel intumescent flame retardant (IFR) system was developed in this study. Ammonium polyphosphate (APP) was efficiently coated with halloysite nanotubes (HNTs) using 3-glycidoxypropyltrimethoxysilane (KH560) as a molecular bridge to obtain a composite flame retardant (HNTs@APP) with enhanced thermal stability and charring performance. This component was synergistically combined with tris(2-hydroxyethyl) isocyanurate (THEIC) and zinc borate (ZB) to construct an efficient IFR system. Remarkably, the experimental results show that the limiting oxygen index (LOI) of composite PP2, which is composed of only 25 wt% HNTs@APP/THEIC, reaches 32.5%; with the introduction of ZB, the flame retardant performance of the composite is further improved. The silicon-boron synergistic effect can efficiently catalyze the dehydration and crosslinking of the polymer matrix, significantly enhance the thermal stability and compactness of the residual carbon layer, thereby synergistically improving the flame retardant, smoke suppression and mechanical properties of the composite. Among them, the LOI of PP4 is increased to 34.5%, the peak heat release rate (pHRR) and total smoke production (TSP) are reduced to 162 kW/m2 and 0.6 m2, decreasing by 88% and 95% compared with pure PP, respectively, and the lowest ID/IG (0.58) is achieved. Meanwhile, its tensile strength and elongation at break are increased to 24.81 MPa and 44.87%, respectively, effectively alleviating the deterioration of the mechanical properties of the PP matrix caused by the addition of flame retardants. This study realizes the synergistic improvement of flame retardant and smoke suppression properties of PP materials at a low flame retardant addition amount, providing a new technical path with good application prospects for the application of PP in safety-critical fields such as electronic and electrical enclosures and building fireproof materials.